A patch was cut from 20ga to fit the cut out with extra metal protruding into the wheel well. The normal test fit, trim, repeat until satisfied routine was followed with this repair. All edges butt welded by first spotting it in, then jumping around to complete the seam with minimal heating and distortion. (figure 1)

Figure 1

Before cutting away the rust, I made a cardboard template of the rear wheel lip from the right side to use while fabricating the wheel opening. (figure 2) Since the wheel openings are mirror images, one template will work on either side.

Figure 2

With the template taped in place, I marked off the wheel opening and the compound curves of the lip. Slits were cut in the patch allowing the metal to be formed duplicating this area.

Figure 3